Valve cartridge assembly for a fluid pump

The present disclosure relates generally to fluid pumps and, for example, to a valve cartridge assembly for a fluid pump.

Hydraulic fracturing is a well stimulation technique that typically involves pumping hydraulic fracturing fluid into a wellbore at a rate and a pressure (e.g., up to 15,000 pounds per square inch (psi)) sufficient to form fractures in a rock formation surrounding the wellbore. This well stimulation technique often enhances the natural fracturing of a rock formation to increase the permeability of the rock formation, thereby improving recovery of water, oil, natural gas, and/or other fluids.

A hydraulic fracturing system may employ one or more fluid pumps for pressurizing hydraulic fracturing fluid. A fluid pump has a suction side, at which low-pressure fluid enters the fluid pump via a suction valve assembly to be pressurized, and a discharge side at which high-pressure fluid pressurized by the fluid pump exits the fluid pump via a discharge valve assembly. A valve assembly may include various components, such as a valve, a valve seat, a spring, a spring retainer, or the like. Each of these components is subject to wear and/or failure, and therefore may be serviced (e.g., reconditioned, repaired, or replaced) from time to time (e.g., about every 100 hours). For example, for servicing, the suction and discharge valve assemblies of the fluid pump may be disassembled and removed from the fluid pump, sometimes using specialized equipment, and then reassembled in the fluid pump following servicing. Accordingly, servicing the suction and discharge valve assemblies of the fluid pump is time consuming and inefficient.

The valve cartridge assembly of the present disclosure solves one or more of the problems set forth above and/or other problems in the art.

A fluid end of a fluid pump may include a fluid end block with a bore in which a plunger is to reciprocate. The fluid end may include a valve cartridge, disposed in the bore and configured for insertion into and removal from the bore as a unit. The valve cartridge may include a valve cartridge housing defining a suction chamber that is open at a first end of the valve cartridge housing and one or more first passageways through the valve cartridge housing that lead into the suction chamber, and a discharge chamber that is open at a second end of the valve cartridge housing, and one or more second passageways through the valve cartridge housing that lead into the discharge chamber. The valve cartridge may include a suction valve assembly including a suction valve that seals the suction chamber, where the suction valve assembly is configured to control flow through the suction chamber. The valve cartridge may include a discharge valve assembly including a discharge valve that seals the discharge chamber, where the discharge valve assembly is configured to control flow through the discharge chamber. The fluid end may include a valve cartridge sleeve, disposed in the bore around the valve cartridge housing, that fluidly connects the suction chamber and the discharge chamber.

A valve cartridge assembly may include a valve cartridge housing defining a suction chamber that is open at a first end of the valve cartridge housing and one or more first passageways through the valve cartridge housing that lead into the suction chamber, and a discharge chamber that is open at a second end of the valve cartridge housing and one or more second passageways through the valve cartridge housing that lead into the discharge chamber. The discharge chamber may be fluidly isolated from the suction chamber through the valve cartridge housing. The valve cartridge assembly may include a suction valve assembly including a suction valve that seals the suction chamber, where the suction valve assembly is configured to control flow through the suction chamber. The valve cartridge assembly may include a discharge valve assembly including a discharge valve that seals the discharge chamber, where the discharge valve assembly is configured to control flow through the discharge chamber.

A fluid pump may include a power end, and a fluid end, coupled to the power end. The fluid end may include a fluid end block with a bore, and a plunger configured to reciprocate with respect to the bore. The fluid end may include a valve cartridge, configured for insertion into and removal from the bore as a unit. The valve cartridge may include a valve cartridge housing defining a suction chamber that is open at a first end of the valve cartridge housing and one or more first passageways through the valve cartridge housing that lead into the suction chamber, and a discharge chamber that is open at a second end of the valve cartridge housing and one or more second passageways through the valve cartridge housing that lead into the discharge chamber. The valve cartridge may include a suction valve assembly including a suction valve that seals the suction chamber, where the suction valve assembly is configured to control flow through the suction chamber. The valve cartridge may include a discharge valve assembly including a discharge valve that seals the discharge chamber, where the discharge valve assembly is configured to control flow through the discharge chamber.

This disclosure relates to a valve cartridge, which is applicable to any positive displacement fluid pump.

is a cross-sectional view of an example fluid pump. The fluid pumpincludes a fluid endand a power end. The fluid endmay be connected to the power endby stay rods. The fluid endincludes a fluid end blockhaving one or more bores(only one shown). For example, the fluid pumpmay include one, two, three, four, five, or more bores. In some implementations, the fluid pumpmay be mounted on a trailer to facilitate transportation of the fluid pumpbetween operational sites. In some implementations, the fluid pumpmay be a hydraulic fracturing pump. For example, the fluid pumpmay have a capability to produce a discharge pressure of at least 8,000 psi, at least 10,000 psi, at least 12,000 psi, or at least 15,000 psi.

The boreis a passageway through the fluid end blockof the fluid end. The fluid endmay include a valve cartridgedisposed in the bore(e.g., a respective valve cartridgemay be disposed in each boreof the fluid end). For example, the valve cartridgeis configured for insertion into, and removal from, the boreas a unit. The valve cartridgeincludes a suction valve assemblyand a discharge valve assembly. The suction valveand the discharge valvemay have different configurations from that depicted in. The boremay be contoured such that when the valve cartridgeis disposed in the bore, the valve cartridgepartitions the boreinto multiple fluidly isolated chambers. The valve cartridgemay be fluidly connected to a suction manifold, and to a discharge manifold.

In operation, fluid is pressurized to a low pressure (e.g., 80 psi) by an outside system (e.g., a centrifugal pump) and pushed through the suction manifoldand through the suction valve assembly. The fluid is then pumped in response to a forward stroke of a plungerand flows through the discharge valve assembly.

In operation, the plungermoves in a plunger boreand is driven by the power endof the fluid pump. The power endincludes a crankshaftthat is rotated by a gearbox output, which is illustrated by a single gear but may be more than one gear. A gearbox inputis coupled to a transmission (not shown) and/or a prime mover (not shown), such as a diesel engine, to rotate the gearbox inputduring operation. A connecting rodmechanically connects the crankshaftto a crossheadvia a wrist pin. The crossheadis mounted within a stationary crosshead housing, which constrains the crossheadto linear reciprocating movement. A pony rodconnects to the crossheadand has its opposite end connected to the plungerto enable reciprocating movement of the plunger.

In operation, movement of the crankshaftcauses the plungerto reciprocate with respect to the bore(e.g., to reciprocate toward and away from the bore). As the plungertranslates away from the bore(a suction stroke of the plunger), the pressure of the fluid on an external side of the suction valve assemblydecreases, which creates a pressure differential across the suction valve assembly. The pressure differential across the suction valve assemblyenables actuation of a valve of the suction valve assemblyto allow the fluid to enter the valve cartridgefrom the suction manifold(e.g., the valve may open responsive to the pressure differential). The pumped fluid is pushed into the valve cartridgeas the plungercontinues to translate away from the bore. As the plungerchanges directions and moves toward the bore(a discharge stroke of the plunger), the fluid pressure inside the valve cartridgeincreases, which creates a pressure differential across the discharge valve assembly. Fluid pressure inside the valve cartridgecontinues to increase as the plungerapproaches the boreuntil the pressure differential across the discharge valve assemblyis great enough to actuate a valve of the discharge valve assemblyand enable the fluid to exit the valve cartridge(e.g., the valve may open responsive to the pressure differential).

The fluid endmay also include a valve cartridge sleevedisposed in the borearound the valve cartridge(e.g., a respective valve cartridge sleevemay be disposed in each boreof the fluid end). For example, the valve cartridge sleeveis configured for insertion into and removal from the boreas a unit (e.g., as a unit with the valve cartridgeor separately from the valve cartridge). The valve cartridge sleeveprovides passageways that facilitate fluid flow through the bore, outside of the valve cartridge, between otherwise isolated chambers of the valve cartridge. In this way, wear caused by high applied pressures in the fluid endis experienced by the valve cartridge sleeverather than the fluid end block.

As indicated above,is provided as an example. Other examples may differ from what is described with regard to.

is a detailed cross-sectional view of an example of the fluid end. As shown, the valve cartridgeand the valve cartridge sleeveare disposed in the borethrough the fluid end block. Together, the valve cartridgeand the valve cartridge sleevemay form a valve cartridge assembly. The valve cartridgemay be arranged in the boreco-axially with the plunger(as shown in). The valve cartridgemay be disposed in the borein an orientation in which the suction valve assemblyis nearer to the plunger, and the discharge valve assemblyis farther from the plunger(as shown in).

The valve cartridgeincludes a valve cartridge housing. The valve cartridge housingmay define a suction chamberthat is open at a first endof the valve cartridge housing. For example, the first endof the valve cartridge housingis open (e.g., unenclosed) and leads into the suction chamber, which is a hollow internal region of the valve cartridge housing. Moreover, one or more passageways(sometimes referred to herein as “first passageways”) are defined through the valve cartridge housingand lead into (e.g., open into) the suction chamber. For example, multiple passagewaysmay be arranged radially around the valve cartridge housing. The passagewaysmay fluidly connect the suction chamberand the bore.

The valve cartridge housingmay also define a discharge chamberthat is open at a second endof the valve cartridge housing. For example, the second endof the valve cartridge housingis open (e.g., unenclosed) and leads into the discharge chamber, which is a hollow internal region of the valve cartridge housing. Moreover, one or more passageways(sometimes referred to herein as “second passageways”) are defined through the valve cartridge housingand lead into (e.g., open into) the discharge chamber. For example, multiple passagewaysmay be arranged radially around the valve cartridge housing. The passagewaysmay fluidly connect the discharge chamberand the bore. The discharge chambermay be fluidly isolated from the suction chamberthrough the valve cartridge housing. For example, there may be no passageways within or through the valve cartridge housingthat fluidly connect the suction chamberand the discharge chamber.

The suction valve assemblyis configured to control flow through the suction chamber. The suction valve assemblymay include a suction valve, a biasing element(e.g., one or more springs, one or more elastomeric bands, or the like), and a valve guide. The suction valvemay seal the suction chamberat the first endof the valve cartridge housing. For example, in a closed position, the suction valveencloses the open end of the suction chamber. The valve guidemay engage a stem of the suction valveto guide actuation of the suction valvein a linear manner. The valve guidehas openings or other discontinuities that allow fluid to flow through the valve guide. The biasing element, which may be held by the valve guide(e.g., the valve guidealso acts as a retainer for the biasing element), is configured to bias the suction valveto the closed position.

The discharge valve assemblyis configured to control flow through the discharge chamber. The discharge valve assemblymay include a discharge valve, a biasing element(e.g., one or more springs, one or more elastomeric bands, or the like), a retainer, and a valve guide. The discharge valvemay seal the discharge chamberat the second endof the valve cartridge housing. For example, in a closed position, the discharge valveencloses the open end of the discharge chamber. The biasing element, held by the retainer, is configured to bias the discharge valveto the closed position. The valve guidemay engage a stem of the discharge valveto guide actuation of the discharge valvein a linear manner. The valve guidehas openings or other discontinuities that allow fluid to flow through the valve guide.

The suction valve assemblyand the discharge valve assemblymay be arranged in the valve cartridge housingin a back-to-back configuration, such that the suction valve assemblyand the discharge valve assemblyopen in opposite directions. For example, the suction valve assemblymay be configured to open the suction valvein a first direction along the bore(e.g., away from the valve cartridge housing), and the discharge valve assemblymay be configured to open the discharge valvein a second direction along the bore(e.g., away from the valve cartridge housing) opposite the first direction. As an example, the suction valve assemblymay be configured to open the suction valvetoward the plunger, and the discharge valve assemblymay be configured to open the discharge valveaway from the plunger.

The valve cartridge sleeveis an annular casing that defines an interior cavityextending a length of the valve cartridge sleeve. The valve cartridge sleeveis arranged around the valve cartridge housing(e.g., the valve cartridge housingis received in the interior cavityof the valve cartridge sleeve). For example, the valve cartridge housingmay be interference fit within the valve cartridge sleeve. Moreover, the valve cartridge sleevemay be interference fit within the bore. In some implementations, the valve cartridge housingand the valve cartridge sleevemay have opposing stops,that restrict relative sliding and properly align the valve cartridge housingand valve cartridge sleeve. Similarly, the boremay have a stopthat further restricts relative sliding of the valve cartridge housingand the valve cartridge sleeve, and that defines a maximum insertion depth of the valve cartridge sleeveinto the bore.

The valve cartridge sleevehas one or more openingsthat extend through the valve cartridge sleeveto the interior cavityof the valve cartridge sleeve. For example, multiple openingsmay be arranged radially around the valve cartridge sleeve. When the valve cartridge sleeveis arranged around the valve cartridge housing, the openingsalign with the first passagewaysthrough the valve cartridge housing, thereby fluidly connecting the suction chamberto the suction manifoldvia the valve cartridge sleeve.

In addition, the valve cartridge sleevehas one or more passagewaysthat extend longitudinally within the valve cartridge sleeve. For example, the passagewaysmay extend within the valve cartridge sleeveparallel to the interior cavityof the valve cartridge sleeve. The passagewaysmay be transverse to the openings. Accordingly, the passagewaysand the openingsare non-intersecting. The passagewaysmay lead to the inner circumferential groovein the valve cartridge sleeve. When the valve cartridge sleeveis arranged around the valve cartridge housing, the inner circumferential groovealigns with the second passagewaysthrough the valve cartridge housing, thereby fluidly connecting the discharge chamberto the borevia the valve cartridge sleeve.

The valve cartridge housingmay include multiple sealing ringsto provide fluid-tight interfaces between the valve cartridge housingand the valve cartridge sleeve. The sealing ringsmay be arranged in the valve cartridge housingon opposite sides of the first passageways(e.g., the first passagewaysare between a pair of sealing rings), and to contact the inner surface of the valve cartridge sleeveon opposite sides of the openings(e.g., the openings are between a pair of sealing rings). Additionally, the sealing ringsmay be arranged in the valve cartridge housingon opposite sides of the second passageways(e.g., the second passagewaysare between a pair of sealing rings), and to contact the inner surface of the valve cartridge sleeveon opposite sides of the inner circumferential groove(e.g., the inner circumferential grooveis between a pair of sealing rings). Additionally, or alternatively, the valve cartridge sleevemay include the sealing ringsat corresponding locations in the valve cartridge sleeve.

During a suction stroke of the plunger, the suction valve assemblyis configured to open the suction valve, thereby causing fluid to flow from the suction manifoldthrough the suction chamber(e.g., via the openingsin the valve cartridge sleeveand the first passageways) and into a suction side (e.g., a plunger side) of the bore. During a discharge stroke of the plunger, the suction valve assemblyis configured to close the suction valve(sealing the suction chamber), and fluid is pumped from the boreinto the discharge chambervia the valve cartridge sleeve(e.g., through the passagewaysof the valve cartridge sleeveand the second passageways). As fluid pressure inside the discharge chamberincreases, during the discharge stroke of the plunger, the discharge valve assemblyis configured to open the discharge valve, thereby causing fluid to flow through the discharge chamberinto a discharge side of the boreand to the discharge manifold.

As indicated above,is provided as an example. Other examples may differ from what is described with regard to.

is a perspective view of an example of the valve cartridge.shows the radial arrangement of the first passagewaysaround the valve cartridge housing, and the radial arrangement of the second passagewaysaround the valve cartridge housing. As further shown, the suction valveand the discharge valveare located at opposite ends of the valve cartridge housing, and open away from a center of the valve cartridge housing.

As indicated above,is provided as an example. Other examples may differ from what is described with regard to.

is a perspective view of an example of the valve cartridge sleeve.shows the radial arrangement of the openingsaround the valve cartridge sleeve.further shows how the passagewaysextend within the valve cartridge sleevetransverse, and non-intersecting with the openings.

As indicated above,is provided as an example. Other examples may differ from what is described with regard to.

The valve cartridge assembly described herein (e.g., including the valve cartridgeand the valve cartridge sleeve) may be used with any positive displacement fluid pump (e.g., a reciprocating positive displacement fluid pump). For example, a fluid pump, such as a hydraulic fracturing pump, having a power end and a fluid end may use the valve cartridge assembly in the fluid end. As described herein, a valve assembly of a fluid pump may include various components, such as a valve, a valve seat, a spring, a spring retainer, or the like, and each of these components are subject to wear and/or failure. Generally, for servicing, the valve assembly may be disassembled and removed from the fluid pump, sometimes using specialized equipment, and then reassembled in the fluid pump following servicing. Accordingly, servicing a valve assembly of the fluid pump can be time consuming and inefficient.

The valve cartridgedescribed herein may include both a suction valve assemblyand a discharge valve assemblyin a unitary part. In particular, the valve cartridgemay be inserted into, or removed from, a bore of a fluid pump as a unit. When the valve cartridgeis inserted into the fluid pump, the suction valve assemblyand the discharge valve assemblyare appropriately positioned to provide control over low-pressure fluid entering the fluid pump and high-pressure fluid exiting the fluid pump. Thus, the valve cartridgefacilitates plug-and-play installation of the suction valve assemblyand the discharge valve assemblyin the fluid pump. After a useful life of the suction valve assemblyand the discharge valve assembly, the valve cartridgemay be removed from the fluid pump and replaced with a new valve cartridge. Accordingly, the valve cartridgeenables fast and efficient servicing of the suction valve assemblyand the discharge valve assembly.

Moreover, the valve cartridge sleeveprovides passagewaysthat facilitate fluid flow through the bore of the fluid pump, outside of the valve cartridge, between otherwise isolated chambers of the valve cartridgeto achieve proper functioning of the valve cartridge. Thus, the valve cartridge sleeveeliminates the need to include such passageways in a fluid end block of the fluid pump. In this way, wear caused by high applied pressures in the fluid pump is experienced by the valve cartridge sleeverather than the fluid end block, thereby extending a useful life of the fluid end block. After a useful life of the valve cartridge sleeve, the valve cartridge sleevemay be removed from the fluid pump and replaced with a new valve cartridge sleeve, which is simpler and more efficient than repairing or replacing of the fluid end block.

The foregoing disclosure provides illustration and description, but is not intended to be exhaustive or to limit the implementations to the precise forms disclosed. Modifications and variations may be made in light of the above disclosure or may be acquired from practice of the implementations. Furthermore, any of the implementations described herein may be combined unless the foregoing disclosure expressly provides a reason that one or more implementations cannot be combined. Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the disclosure of various implementations. Although each dependent claim listed below may directly depend on only one claim, the disclosure of various implementations includes each dependent claim in combination with every other claim in the claim set.

As used herein, “a,” “an,” and a “set” are intended to include one or more items, and may be used interchangeably with “one or more.” Further, as used herein, the article “the” is intended to include one or more items referenced in connection with the article “the” and may be used interchangeably with “the one or more.” Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Also, as used herein, the term “or” is intended to be inclusive when used in a series and may be used interchangeably with “and/or,” unless explicitly stated otherwise (e.g., if used in combination with “either” or “only one of”).